Method for producing a stimulation electrode

ABSTRACT

A stimulation electrode is provided having an electrically conducting electrode base member which is partially covered with an electrically insulating ceramic layer. The ceramic layer is formed of an oxide and/or an oxynitride of at least one metal of the group of titanium, niobium. tantalum, zirconium, aluminum and silicon. Various methods are provided for production of the stimulation electrode, including methods in which the ceramic layer is formed in situ by a thermal, chemical or electrochemical oxidation or oxynitridation process. The stimulation electrode may be used as a cardiac pacemaker electrode, a neuro-stimulation electrode, or another human implant.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of pending U.S. patentapplication Ser. No. 12/202,790, filed on Sep. 2, 2008, entitled “Methodfor Producing a Stimulation Electrode,” which is a divisionalapplication of U.S. patent application Ser. No. 10/735,069, filed onDec. 12, 2003, entitled “Stimulation Electrode and Methods of Making andUsing Same,” now U.S. Pat. No. 7,421,299.

BACKGROUND OF THE INVENTION

The invention is directed to a stimulation electrode with anelectrically conducting electrode base member, which is partiallycovered with an electrically insulating ceramic layer, wherein theceramic layer is formed from an oxide and/or an oxynitride of at leastone of the metals selected from the group of titanium, niobium,tantalum, zirconium, aluminum, and silicon. The invention is furtherdirected to the production of such a stimulation electrode and the useof such a stimulation electrode.

European published patent application EP 1 169 972 A1 discloses acatheter, which is equipped with a stimulation electrode. Anelectrically insulating and thermally conductive layer is arranged inthe region of the stimulation electrode and can be formed of ceramic,among other things. The thickness of the electrically insulating andthermally conductive layer is <10 μm.

European Patent EP 0 620 024 B1 discloses stimulation electrode, whichhas a high-ohmic insulating layer on the electrode tip. A diamond-likecarbon, which is extremely biocompatible, is particularly preferredhere. The diamond-like carbon can be deposited using a laser, amongother things. It is furthermore disclosed that the entire electrode headmay be coated with a diamond-like carbon layer and thereafter thestimulation surfaces may be freed, as desired, by photoetching.

U.S. Pat. No. 6,298,272 B1 discloses a cardiac pacemaker electrode,which is provided with an insulating coating in the region of theelectrode tip. The insulating coating here can be formed, for example,by dipping, printing, spraying on, painting on, and resist techniques.

International patent application publication WO 98/31419 discloses acardiac pacemaker electrode, in which the electrode tip has an annular,electrically insulating sheathing. Plastics or elastomers, particularlysilicone rubber, are disclosed here as materials for this sheathing.

German published patent application DE 35 18 317 A1 discloses astimulation electrode, which is partially coated with insulatingmaterial. Plastic is disclosed here as the coating material.

BRIEF SUMMARY OF THE INVENTION

The invention now has as an object the provision of a stimulationelectrode with very good biocompatibility and high long-term corrosionresistance and which at the same time can be produced rapidly andinexpensively.

The object is attained for the stimulation electrode set for the at theoutset in that the electrode base member is further coated, at leastpartially, with an electrically conducting layer of titanium nitride,niobium nitride, tantalum nitride, zirconium nitride, aluminum nitride,silicon nitride, vanadium nitride, iridium oxide, or an alloy ofplatinum and iridium, wherein the iridium portion of the alloy is ≧21wt. % and the platinum portion of the alloy is ≧ about 100 ppm.

These materials have a particularly good biocompatibility and can beapplied with excellent adhesion to electrically conducting electrodebase members. The following description of suitable production methodsfor the ceramic layer shows that these materials can be used in a simpleand inexpensive manner.

In particular, it has been found to be advantageous if the electrodebase member here is formed of titanium, tantalum, gold, carbon,platinum, iridium, a platinum-iridium alloy, an alloy based on cobaltand/or nickel, or stainless steel.

The ceramic layer can then be applied on the electrically conductinglayer. However, the ceramic layer can also be applied adjacent to theelectrically conducting layer on the electrode base member.

It has furthermore been found advantageous to coat the electrode basemember, at least partially, with an electrically conducting layer oftitanium nitride or with a titanium nitride layer. The ceramic layerhere can then be applied both on the electrically conducting layer oftitanium nitride and also adjacent the electrically conducting layer oftitanium nitride on the electrode base member.

It is advantageous here if the electrically conducting layer of titaniumnitride is at least partially covered with at least one oxidationprotection layer on its side facing away from the electrode base member.This is of particular advantage when the stimulation electrode is to beused with anodic polarity, since the long-term durability of thestimulation electrode is significantly increased thereby.

The ceramic layer here can be applied on the at least one oxidationprotection layer, or instead adjacent the electrically conducting layerof titanium nitride, and the at least one oxidation protection layer canbe applied on the electrode base member.

It is furthermore possible for the ceramic layer to be applied adjacentthe at least one oxidation protection layer on the electricallyconducting layer of titanium nitride.

It has been found to be particularly advantageous for the at least oneoxidation protection layer to be formed from at least one element of thegroup platinum, iridium, and gold. However, it is also possible to formthe oxidation protection layer of an oxide, a carbide, a nitride, or apolymer, wherein the at least one oxidation protection layer reduces theimpedance electrode base member coated with the electrically conductinglayer of titanium nitride, or at most increases it to a value which issmaller than the impedance of the uncoated electrode base member.

The thickness of the oxidation protection layer is advantageously in therange of about 500 nm to about 5 μm.

Thicknesses of about 1 nm to about 20 μm have been found to beadvantageous for the ceramic layer; wherein the layer thickness dependsheavily on the production method used for forming the ceramic layer.

The ceramic layer can have a surface which is closed in itself orinstead can be formed by plural independent surfaces.

The object is attained for a first method of manufacture of thestimulation electrode in that the ceramic layer is formed by a PVD(physical vapor deposition) method, a CVD (chemical vapor deposition)method, or a dip, spray, or sol-gel method. As suitable PVD methods, forexample, cathode sputtering, thermal vaporization, electron beamvaporization, or arc vaporization may be considered.

The object is attained for a second method of production of thestimulation electrode, in that the ceramic layer is formed by depositinga metallic layer of titanium and/or niobium and/or tantalum and/orzirconium and/or aluminum and/or silicon, and in that a thermal orelectrochemical or chemical oxidation or oxynitriding of the metalliclayer subsequently takes place. This method can be performedparticularly simply and cost-effectively.

The object is attained for a third method of production of a stimulationelectrode with a titanium electrode base member, in that the ceramiclayer is formed by the electrode base member being partially oxidized,thermally or chemically, to titanium oxide.

The object is attained for a fourth method of production of astimulation electrode with a tantalum electrode base member, in that theceramic layer is formed by the electrode base member being partiallyoxidized, thermally or chemically, to tantalum oxide.

The third and fourth methods according to the invention make possiblethe direct formation of the ceramic layer from the material of theelectrode base member, so that a separate application of material forthe ceramic layer is not required.

The object is attained for a fifth method of production of a stimulationelectrode, in which the electrode base member is at least partiallycovered with an electrically conducting layer of titanium nitride, inthat the ceramic layer is formed by the electrically conducting layer oftitanium nitride being partially oxidized, thermally orelectrochemically, to titanium oxide, wherein the oxidation comprises atleast a portion of the layer thickness of the electrically conductinglayer of titanium nitride.

For the second through fifth methods according to the invention, it hasbeen found to be particularly advantageous to perform the thermaloxidation with a laser.

For the first through fifth methods according to the invention, it hasfurther been found to be advantageous if the ceramic layer is firstformed over the full surface on the uncoated or coated electrode basemember, and it is then partially removed again by etching.

The use of the stimulation electrode according to the invention is idealas a cardiac pacemaker electrode, neuro-stimulation electrode, retinalimplant, cochlear implant, or in another human implant.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofthe invention, will be better understood when read in conjunction withthe appended drawings. For the purpose of illustrating the invention,there are shown in the drawings embodiments which are presentlypreferred. It should be understood, however, that the invention is notlimited to the precise arrangements and instrumentalities shown. In thedrawings:

FIG. 1 is a schematic side view of an electrode base member made oftitanium with a ceramic layer;

FIG. 2 is a schematic side view of an electrode base member made ofstainless steel with a ceramic layer;

FIG. 3 is a schematic side view, partially in section, of a stimulationelectrode according to the invention with a titanium electrode basemember having a titanium nitride coating;

FIG. 4 is a schematic side view, partially in section, of a stimulationelectrode according to the invention with a platinum-iridium alloyelectrode base member; and

FIGS. 5-8 are schematic side views, partially in section, of stimulationelectrodes according to the invention with a titanium electrode basemember having a titanium nitride coating and an oxidation protectionlayer.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows an intermediate product 1 in the production of thestimulation electrode according to the invention with a titaniumelectrode base member 2, which was superficially oxidized by a laser toa ceramic layer 3 of titanium oxide.

FIG. 2 shows and intermediate product 1 a in the production of thestimulation electrode according to the invention with a stainless steelelectrode base member 2 a. A ceramic layer 3 a of aluminum oxide, formedby electron beam vaporization, is applied on the electrode base member 2a.

FIG. 3 shows a stimulation electrode 1 b with a titanium electrode basemember 2 b. The electrode base member 2 b here is coated with a titaniumnitride layer 4 b. The titanium nitride layer 4 b was partially oxidizedby electrochemical oxidation to titanium oxide with formation of theceramic layer 3 b.

FIG. 4 shows a stimulation electrode 1 c with an electrode base member 2c of a platinum-iridium alloy with 10 wt. % iridium content. Theelectrode base member 2 c here is covered with a layer 4 c of iridiumoxide. A ceramic layer 3 c of tantalum oxide is applied on the layer 4 cand was formed by the vapor deposition of metallic tantalum andsubsequent thermal oxidation of the tantalum.

FIG. 5 shows a stimulation electrode 1 d with a titanium electrode basemember 2 d. The electrode base member 2 d is covered with a titaniumnitride layer 4 d, which in turn is overcoated with an iridium oxidationprotection layer 5 d. A titanium oxide ceramic layer 3 d, applieddirectly on the electrode base member 2 d, is arranged adjacent to thetitanium nitride layer 4 d and also the iridium oxidation protectionlayer 5 d. The ceramic layer 3 d here is formed of titanium oxide, whichwas formed by application of metallic titanium and subsequent thermaloxidation by a laser.

FIG. 6 shows a stimulation electrode 1 e with a titanium electrode basemember 2 e. The electrode base member 2 e here is covered with atitanium nitride layer 4 e, which in turn is partially covered with aplatinum oxidation protection layer 5 e. In the region in which theoxidation protection layer 5 e does not cover the titanium nitride layer4 e, a titanium oxide ceramic layer 3 e is formed by oxidation of thetitanium nitride layer 4 e.

FIG. 7 shows a stimulation electrode 1 f with a titanium electrode basemember 2 f, which is coated with a titanium nitride layer 4 f. Thetitanium nitride layer 4 f is partially coated with an iridium oxidationprotection layer 5 f. In the regions of the titanium nitride layer 4 fnot covered with the oxidation protection layer 5 f, the titaniumnitride layer 4 f is superficially converted into a titanium oxideceramic layer 3 f by thermal oxidation with a laser.

FIG. 8 shows a stimulation electrode 1 g with a titanium electrode basemember 2 g, which is covered with a titanium nitride layer 4 g. Thetitanium nitride layer 4 g is further covered with a platinum-iridiumalloy oxidation protection layer 5 g. A ceramic layer 3 g of zirconiumoxide, formed by a CVD method, is applied on the oxidation protectionlayer 5 g.

It will be appreciated by those skilled in the art that changes could bemade to the embodiments described above without departing from the broadinventive concept thereof. It is understood, therefore, that thisinvention is not limited to the particular embodiments disclosed, but itis intended to cover modifications within the spirit and scope of thepresent invention as defined by the appended claims.

1. A method for producing a stimulation electrode comprising anelectrically conducting electrode base member partially covered with anelectrically insulating ceramic layer, wherein the ceramic layer (3, 3a, 3 b, 3 c, 3 d, 3 e, 3 f, 3 g) is formed of an oxide and/or anoxynitride of at least one metal selected from the group consisting oftitanium, niobium. tantalum, zirconium, aluminum, and silicon, andwherein the electrode base member (2, 2 a, 2 b, 2 c, 2 d, 2 e, 2 f, 2 g)is further at least partially coated with an electrically conductinglayer (4 b, 4 c, 4 d, 4 e, 4 f, 4 g) comprising at least one materialselected from the group consisting of titanium nitride, niobium nitride,tantalum nitride, zirconium nitride, aluminum nitride, silicon nitride,vanadium nitride, iridium oxide, and an alloy of platinum and iridium,wherein the iridium portion of the alloy is ≧21 wt. % and the platinumportion of the alloy is ≧ about 100 ppm, wherein the electrode basemember (2, 2 a, 2 b, 2 c, 2 d, 2 e, 2 f, 2 g) is made of tantalum, andthe ceramic layer (3, 3 a, 3 b, 3 c, 3 d, 3 e, 3 f, 3 g) is formed by atleast partially oxidizing the tantalum electrode base member (2, 2 a, 2b, 2 c, 2 d, 2 e, 2 f, 2 g) to tantalum oxide by thermal orelectrochemical oxidation.
 2. The method according to claim 1, whereinthe thermal oxidation takes place by a laser.
 3. A method for producinga stimulation electrode comprising an electrically conducting electrodebase member partially covered with an electrically insulating ceramiclayer, wherein the ceramic layer (3, 3 a, 3 b, 3 c, 3 d, 3 e, 3 f, 3 g)is formed of an oxide and/or an oxynitride of at least one metalselected from the group consisting of titanium, niobium, tantalum,zirconium, aluminum, and silicon, and wherein the electrode base member(2, 2 a, 2 b, 2 c, 2 d, 2 e, 2 f, 2 g) is further at least partiallycoated with an electrically conducting layer (4 b, 4 c, 4 d, 4 e, 4 f, 4g) comprising at least one material selected from the group consistingof titanium nitride, niobium nitride, tantalum nitride, zirconiumnitride, aluminum nitride, silicon nitride, vanadium nitride, iridiumoxide, and an alloy of platinum and iridium, wherein the iridium portionof the alloy is ≧21 wt. % and the platinum portion of the alloy is ≧about 100 ppm, wherein the electrode base member (2, 2 a, 2 b, 2 c, 2 d,2 e, 2 f, 2 g) is made of titanium, and the ceramic layer (3, 3 a, 3 b,3 c, 3 d, 3 e, 3 f, 3 g) is formed by at least partially oxidizing thetitanium electrode base member (2, 2 a, 2 b, 2 c, 2 d, 2 e, 2 f, 2 g) totitanium oxide by thermal or electrochemical oxidation.
 4. The methodaccording to claim 3, wherein the thermal oxidation takes place by alaser.